EFFECT OF GRINDING PROCESS PARAMETERS ON GRINDING FORCE OF ALUMINIUM ALLOYS (AA6061-T6) ALEXIUS ANAK AN’YAN A final year report submitted in partial fulfillment of the requirements for the award of the degree of Bachelor of Mechanical Engineering with Manufacturing Faculty of Mechanical Engineering Universiti Malaysia Pahang NOVEMBER 2008
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EFFECT OF GRINDING PROCESS PARAMETERS ON GRINDING FORCE OF
ALUMINIUM ALLOYS (AA6061-T6)
ALEXIUS ANAK AN’YAN
A final year report submitted in partial fulfillment of the
requirements for the award of the degree of
Bachelor of Mechanical Engineering with Manufacturing
Faculty of Mechanical Engineering
Universiti Malaysia Pahang
NOVEMBER 2008
ii
Dedicated to all my beloved family members especially to
my father, mother, and sister.
iii
UNIVERSITI MALAYSIA PAHANG
FACULTY OF MECHANICAL ENGINEERING
We certify that the report written by Alexius Anak An’yan entitled “Effect of grinding process
parameters on grinding force of aluminium alloys (AA6061-T6)”.We have examined the final
copy of this project and that in our opinion; it is fully adequate, in terms of scope and quality for
the awarding the degree. We herewith recommend that it be accepted in fulfillment of the
requirements for the Degree in the Mechanical Engineering with Manufacturing.
Committee members of Final Examination:
Name Signature
1. Mdm. Siti Haryani binti Tomadi
2. Dr. Daw Thet Thet Mon
3. Mr. Mahendran a/l Samykano
Approved for Coordinator of Faculty of Mechanical Engineering
iv
SUPERVISOR’S DECLARATION
I hereby declare that I have checked this project and in my opinion this project is
satisfactory in terms of scope and quality for the award of the degree of Bachelor of
Mechanical Engineering with Manufacturing
Name of Supervisor: Mr. Mohd Azmir Bin Mohd Azhari
Position: Lecturer / Final Year Project Supervisor
Date:
Signature:
v
STUDENT’S DECLARATION
I hereby declare that the work in this thesis is my own except for quotations and
summaries which have been duly acknowledged. The thesis has not been accepted
for any degree and is not concurrently submitted for award of other degree.
Name: Alexius anak An’yan
ID Number: ME05014
Date:
Signature:
vi
ACKNOWLEDGEMET
In preparing this thesis, I was in contact with many people, academicians,
and practitioners. They have contributed towards my understanding and thoughts.
In particular, I wish to express my sincere appreciation to my main thesis
supervisor, Mr. Mohd Azmir Bin Mohd Azhari, for encouragement, guidance,
critics and friendship. Without his continued support and interest, this thesis would
not have been the same as presented here.
I am also indebted to Universiti Malaysia Pahang (UMP) for funding my
Bachelor Degree study. Librarians at UMP also deserved special thanks for their
assistance in supplying the relevant literatures.
My sincere appreciation also extends to all my colleagues and others who
have provided assistance at various occasions, whether directly or indirectly. Their
views and tips are useful indeed. Unfortunately, it is not possible to list all of them
in this limited space. I am also grateful to all my family members who supported
me throughout these years. Last but not least, thanks to Lord for letting me making
this Final Year Thesis a success and become my fruitful moments.
vii
ABSTRACT
Significant developments have recently been made in the grinding of metals.
Many researches have been devoted to determining the effect of these grinding
parameters towards grinding force. The aim of this project is to study the effect of
grinding process parameters namely depth of cut, number of passes, and use of
coolant on grinding force of aluminium alloy (AA6061-T6). A three component
force transducer dynamometer (Kistler Model Type 5070) was used to measure
grinding forces in this experiment. A full factorial experimental design was used as
the approach for the design of experiment. Through the analysis of variance
(ANOVA) conducted, it was found that the most significant parameter is the usage
of coolant followed by depth of cut. Meanwhile, number of passes was found to be
not significant. In conclusion, the grinding force values increased as the number of
passes became higher in proportional to depth of cut. The grinding force also
increased if running in dry condition.
viii
ABSTRAK
Pemipisan logam semenjak akhir ini makin telah memberi kesan ketara yang
nyata. Banyak kajian telah telah diperuntukkan untuk mengenal pasti kesan proses
pemipisan terhadap daya pemipisan. Projek ini bertujuan untuk mengkaji kesan
proses pemipisan terhadap daya pemipisan pada aluminium aloi (AA6061-T6). Tiga
komponen daya sensor jenis “ Kistler Model Type 5070” digunakan dalam kajian
ini. Kaedah faktorial penuh digunakan dalam reka bentuk eksperimen ini. Matlamat
analisa variasi dalam projek ini adalah untuk mengkaji jenis parameter yang
mempunyai kesan besar terhadap daya pemipisan aluminium aloi (AA6061-T6).
Melalui analisa variasi (ANOVA) yang dijalankan, ditemui bahawa parameter yang
paling mempengaruhi adalah penggunaan pelincir dan kedalaman pemotongan
Manakala, bilangan laluan pemipisan didapati tidak mempunyai pengaruh yang
besar. Kesimpulannya, nilai daya pemipisan akan meningkat sekiranya bilangan
laluan pemipisan bertambah berkadar dengan kedalaman pemotongan. Daya
pemipisan turut bertambah jika proses keadaan tanpa pelincir dijalankan.
ix
LIST OF CONTENTS
CHAPTER TITLE PAGE
PANEL’S DECLARATION iii
SUPERVISOR’S DECLARATION iv
STUDENT’S DECLARATION v
ACKNOWLEDGEMENTS vi
ABSTRACT vii
ABSTRAK viii
LIST OF TABLES xii
LIST OF FIGURES xiii
LIST OF SYMBOLS AND ABBREVATIONS xiv
LIST OF APPENDICES xvi
1 INTRODUCTION
1.1 Introduction 1
1.2 Problem statement 2
1.3 Objectives 2
1.4 Scope 2
1.4.1 To study about the machine and material 2
1.4.2 To design the experiment 3
1.4.3 Analysis of Data 3
1.4.4 Interpreting data 3
x
1.5 Arrangement of report 3
1.5.1 Flow chart 4
2 LITERATURE REVIEW
2.1 Introduction 5
2.1.1 Aluminium alloys 6
2.2 Machining of aluminium alloys (AA6061) 6
2.2.1 Milling process 6
2.2.2 Turning process 7
2.2.3 Grinding process 7
2.2.4 Unconventional machining 9
i. Electricdischarge machining (EDM) 9
ii. Electrochemical machining ( ECM) 9
iii. Water Jet Machining (WJM) 9
2.3 Grinding of Aluminium Alloys (AA6061-T6) 10
2.3.1 Effects of multi-pass cutting on grinding forces 10
2.3.2 Effects of depth of cut on grinding forces 12
2.3.3 Effects of coolant lubricant on grinding forces 13
2.3.4 Effects of other parameters 13
3 METHODOLOGY
3.1 Introduction 14
3.2 Material properties 15
3.2.1 Grinding process 16
3.3 Experimental Setup 19
3.3.1 Selection & Parameter 19
xi
3.3.2 Experiment layout 20
3.3.3 Conducting experiment procedures 21
3.4 Management of result 23
3.4.1 Analysis of Result 23
3.4.2 Analysis of Variance 24
4 RESULTS
4.1 Introduction 25
4.2 Result of Experiment 25
4.3 Analysis Graph of Result 28
4.4 Analysis of Grinding Force Data using ANOVA 32